Method of making a carboy



Oct. 23, 1956 J. D. sARTAKol-'F METHOD'OF MAKING A CARBOY Filed Sept.19, 1950 5 Sheets-Sheet l -INVENTOR SHRTAKQFF ATToR Y V v o J v f v PT..W1 lv f 4. l. /1 H Y 01u /rff//ll//l/l//f//f/w/f/////////////// Il ZOct. 23, 1956 J. D.sARTAKoFF METHOD oF MAKING A CARB'OY' 5 Sheets-Sheet2 f` Filed sept. 19. 195o INVEN-roR Wick 0 SAPMKOFF @my W ATTORNEY Oct.23, 1956 J, D, SARTAKOFF 2,768,106V

METHOD OF MAKING A CARBOY 'Filed sept. 19, '195o 5 sheetssheet s PJ.- E1E INVENTOR Z2/CK D. 54pm/UFF TIE' i5 #WW ATTOR EY OC- 23, 1956 .L D.sARTAKoFF 2,768,106

.METHOD oF MAKING A cARBoY Filed sepulg, 195o 5 Shapis-Sheet 4 ATTORNOct 23, 1956 J. D. sARTAKox-F 2,768,106v

.METHOD OF MAKING A CARBOY Filed Sept. 19, 1950 FLE .1.7

5 Sheets-Sheet 5 F 1.5' .LE-

. -INVENTOR Jqcx D. Senago/:F

ATTORNEY United States Patent O ivmrnon or MAKING A CARBoY Jack D.Sartakoff, Douglaston, N. Y. Application september 19, 1950, serial No.185,600

12 claims. (c1. 154-83) This invention relates to methods of makingnovel receptacles and containers adapted for a wide variety of purposesbut, for the purpose of illustration, these methods are herein describedin connection with the manufacture of carboys such as are used for thestorage and shipment of acids, alkalis and other strong chemicals.

Heretofore carboys have universally been made in the form of glassbottles, with the body of the bottle housed within a wooden box or cratewith the neck of the bottle projecting through an opening in the top ofthe crate. Various devices have been provided, usually in the form ofwooden strips nailed to the top of the box, to cover and protect theneck of the bottle during shipment.

Glass bottle carboys are expensive to manufacture, are apt to becomebroken, are heavy to handle and involve relatively high transportationcosts. There has long been an urgent need for a lighter, stronger, moredurable and less expensive construction, but prior to the presentinvention no satisfactory substitute for glass has been found.

One object of the present invention is to provide a carboy wherein thecontainer for the acids or other liquids is made from an organic plasticof non-friable character, so that it will not be broken by shocks whichwould splinter glass and will permit the manufacture of a carboy of verylight weight as compared with the conventional glass bottle.

The problems of making a carboy container of organic plastic arenumerous and dilicult to overcome for there are only a relatively feworganic plastics which are not attacked or destroyed by strong acids andalkalis and those few plastics which are suitable and resistant to suchreaction are extremely difficult to fabricate into containers of sizescomparable to the sizes of conventional carboys. Polyethylene is such aplastic and, while it is possible to make very small containers, such aslittle bottles, of polyethylene by processes known to the art, it hasbeen utterly impractical and impossible to make, by such processes, abottle of this material large enough to function as a carboy. Theproblem therefore was to provide a method whereby a container ofrequisite size could be formed and to make this container sufficientlystrong to withstand the rough handling to which carboys are subjected inuse.

As a result of protracted experimentation and tests, I have been able tomake such a container and an appropriate housing or crate therefor andthus fabricate a complete carboy which has satisfactorily withstood alltests required of conventional carboys and which is lighter, moreeconomical and durable than the glass bottle carboys.

According to the preferred method of this invention, the container ofthe carboy is fabricated from two sheets of organic plastic which areclamped between two oppositely chambered molds and respectively expandedinto the respective chambers of said molds, preferably by hydraulicpressure introduced between the sheets. The molds are clamped upon thesheets tightly enough to hold the molds together and yet permit thesheets, which are initially oversize, to creep through the joint betweenthe molds and permit the expansion of the sheets into substantialconformation with the mold cavities without undue strain on any portionof either sheet. With this procedure, it is possible to make twosections, constituting the two lateral halves of a container, with thewalls of both sections of substantially uniform thickness throughout andwithout strain or undesirable thinning at any particular portion ofeither section. In carrying out this shaping step, the liquid used asthe hydraulic pressure medium may be at an elevated temperature tofacilitate shaping of the plastic without undue strain or the sheets maybe externally heated or both.

After the two sections of the container are formed as stated, surplusportions of the sheets which extend from the shaped areas thereof, aretrimmed to leave iins of substantially uniform width and these fins arethen marginally heat sealed to one another, and an appropriate tubularneck of the same or of a compatible organic plastic is heat sealed tothe assembled sections.

Thereafter said fins are enclosed within a, metallic binder which isbent a plurality of times to tightly clamp the fins together. Themetallic binding is, prior to its application to the ns, preferablycoated or otherwise covered with organic plastic resistant to strongacids and alkalis, so that even though these liquids are spilled overthe exterior of the container, the metallic binding will be protectedagainst attack or damage thereby.

The carboy container, fabricated as described, is preferably housedwithin a housing which may be of wood or any other appropriate material.This housing is internally slotted to receive the metallic bindings andapertured for the passage of the neck of the container. The housing,moreover, is so constructed as to grip and hold the neck againstwithdrawal into the interior of the housing and said housing is alsoprovided with a neck guard of novel construction, hereinafter more fullydescribed, which functions to protect the neck against contact withextraneous objects.

An important feature of this invention consists in the conjoint use ofboth the heat sealed joint or union and the metallic binding, soassociated with one another that the former serves to produce a liquidtight joint, while the latter serves to bind sections together. Theirrelation should be such that the heat seal is within the connes of thebinding and is protected thereby from the tension and other strains orstresses imposed by the liquid load in the container.

The reason for this relation is that the operation of heat sealingpolyethylene and certain other plastics, tends or serves to change and,in some cases, destroy the normal orientation of the plastic structureand materially decrease its ability to withstand tearing and rupturingstrains and stresses. Thus, while a satisfactory and durable liquid sealmay be thus produced, it is a seal which, per se, lacks the necessarystrength to confine a heavy body of liquid. This seal is, therefore,formed along the margin of the ns which project from the cavities of thesections and then the whole iin is wrapped within the metal bindingwhich grips and holds those portions of the fin which are remote fromand thus unaffected by the heat sealing operation and are consequentlywell able to carry the liquid load.

The metal binding may be made sufficiently strong to eifectually bindthe sections together, or it may be, in turn, enclosed within a channelto reinforce it. This channel may be formed in a box, crate or otherappropriate housing or it may be in the form of metal channel sectionaccording to the use to which the container is to be put.

Another feature of this invention resides in the novel methods of heatsealing plastics, hereinafter described,

whereby the effect of the applied heat is localized in the zones wherethe union is desired and not permitted to spread and weaken otherportions or strata of the plastic sheets.

Features of the invention, other than those adverted to, will beapparent from the hereinafter detailed description and claims, when readin conjunction with the ac companying drawings.

The accompanying drawings illustrate different methods of making thecarboy of this invention, but the showing thereof is to be understood asillustrative, only, and not as defining the limits of the invention.

Fig. l an exploded perspective view showing two separate chamberedmolds, with two sheets of organic plastic between them, positioned onopposite sides of collapsed distendable pressure bag.

Fg. 2 is a section through the same parts with the molds clampedtogether and with the pressure bag still collapsed.

ig. 3 is a face view of the arrangement illustrated in fa rig. 4 is aview similar to Fig. 2 out showing the condition ot the parts with thebag distended to press the plastic sheets into substantial conformitywith the mold cavities.

F g. 5 is a side elevation of the parts at the conclusion of ti e methodstep ot Fig. 4.

6 is a face View showing how the formed sheet plastic sections appearafter they have been removed from the molds and trimmed to size at theiredges.

6A shows a modified form of trimming with the corners cut oli.

Fig. 7 shows the next step of heat sealing the margin of: the fins atthe edfes of the plastic sections.

Fig. 3 shows one method of effecting this sealing while limiting theheating to the marginal peripheral portion of the fins.

Fig. 8A is similar to Fig. 8 but shows a modification of such method.

9 shows the next step wherein the neck is heat .f ed to the assembledsections.

ig. l@ is a section taken at the line IO- of Fig. 9 showing how pressureis applied and the seal subsequently cooled during the step of Fig. 9.

lt shows the step of heat sealing the tins of the two sections to oneanother in the region adjacent the neck.

Fig. l2 is an exploded View illustrating in'perspective cornerreinforcing inserts, the manner of preliminarily folding t. e tins forthe reception of the metallic binder, and the mode oi applying saidbinder.

i3 is also a perspective of one corner of the container with the partsof Fig. l2 in iinished, assembled condition.

litis a section on the line lli-14 of Fig. l3 and l5 is a face view ofthe Completed container. Fig. 16 is a perspective view of the woodenhousing for the carboy container, certain parts being broken away toshow adjacent parts in section.

Fig. i7 is a fragmental section on the line ifi-i7 of Fig. 16, butshowing the container within the housing.

Fig. 1S is a like view on the line .t3-18 of Fig. i6.

Fig. i9 shows the present invention as embodied in a cylindrical carboy.rThis view shows the cover and a part of the housing in central section.

Fig. 20 is a horizontal section on the line 2lb-Ztl of Fig. i9, with thecontainer omitted.

Fig. 2l is a fragmental perspective showing a modified methodpreliminarily peripherally sealing the plastic sheets together to renderunnecessary the use of a pressure bag in the step of initially shapingthese plastic sheets.

The method as shown in the drawings is carried out through the use of amold couple comprising'two molds designated l in Fig. l, and havingchambers 2 withopen tops 3. While the molds are separated, as shown inthis figure, there is placed between them two sheets of organic plasticP. These sheets may be entirely separate from one another or they may beparts of a single sheet folded intermediate its ends. The sheets P areplaced between the members of the mold couple and between these sheetsis interposed a pressure bag 4 of any appropriate distendable material,such as rubber. The bag 4, when deflated, is of a size smaller than themold cavities and is substantially flat. The sheets P are of overallsize somewhat larger than the meeting iianges of the molds. The pressurebag is provided with a stoppered neck, 5, shown at its top in Figs. l, 2and 4, and the mold flanges are recessed at 6 to accommodate this neck.

The initial. step in fabricating the container consists in ciamping theplastic sheets and pressure bag between the molds by any appropriateclamping devices to produce the assembly shown in Figs. 2 and 3. Whenthe parts are thus clamped together it will be noted from Fig. 3 thatthe sheets P project beyond the periphery of the mold llanges so as toprovide extra material which may be drawn into the mold cavities ashereinafter more fully explained. The clamping is so regulated that thetop flanges of the mold grip the plastic sheets tightly between themwhile the lateral and bottom flanges are not clamped so tightly in orderto permit the corresponding portions of the sheets which extend beyondthe flanges to creep inwardly to supply the stock necessary to providethe formed sections without undue strain or attenuation of the wells ofthe sheet stock.

As shown best in Fig. 2 the stopper' of the neel: 5 of the pressure bagis perforated for the passage of three tubes of a hydraulic-pneumatictubing system. in this system, hot water at a suticiently elevatedtemperature to soften the plastic and facilitate its shaping, may be fedunder pressure through a supply tube '7 from any suitable source. Thistube has several branches. One branch 3, valved at 9, extends downwardlythrough the stopper to substantially the base of the bag 4. Two otherbranches 19, valved at i1, extend into the upper open ends 3 of the moldchambers and the branch 8 is provided with a drawoff 12, valved at 13.

Cold water is supplied under pressure from a suitable source through atube 14 which has two branches 15. These branches 15, valved at 16, leadto the open tops of the mold cavities. Compressed air may be fed throughtube 17, valved at 18, and leading through the stopper to the interiorof the pressure bag. This tube 17 has a vent 19 to the atmosphere and isvalved at 20. Another tube 2.1'1eads from the interior of the pressurebag through the stopper to a pressure gauge 22 and is connected to apressure relief valve 23.

After the parts have been assembled as described and as shown in Fig. 2(all of the valves of the hydraulicpneumatic system being closed) themethod proceeds as follows: Hot water is used to soften the plasticsheets. Such water may be introduced into the mold cavities as shown inFig. 2 or these mold cavities may be left empty and hot Water introducedonly into the bag. To introduce the hot water into the mold cavities 2,the valves 11 are opened and these cavities are lled as shown in Fig. 2.The valves 11 are then closed. The valve 9 is then opened to allow hotwater, under adequate pressure, to pass through the branch 8 into theinterior of the pressure bag. The valve 20 is then opened to permitentrapped air to escape from the bag to the atmosphere through vent 19and hot water is permitted to ilow into the bag and cause same to behydraulically distended.

As the bag distends, it forces the plastic sheets softened by hot waterboth interiorly and externally thereof, to substantially conform to themold cavities 2 as shown in Fig. 4. The vent valve 20 is closed as soonas entrained air has been evacuated from the bag in order that hydraulic.pressure may be applied to distend the bag as stated. As the bagisdistendedand the sheets conformed to the mold cavities, the hot water insaid cavities exteriorly of the sheets is displaced and overflows thecavities 2 through the open tops 3 so that there is little if any waterleft in these cavities when the shaping of the plastic sheets has beenconcluded as shown in Fig. 4. Any Water which may remain in thesecavities may then be drawn off through valved drawofs 26.

It will be noted from Fig. 3, that at the beginning of this forming stepof the method, when the sheets are substantially flat, such sheets willextend very appreciably beyond the flanges of the molds. However, as thesheets are formed, portions thereof are permitted to creep into thespace between the molds in order that a suicientl mass of material mayautogenously -creep into the mold cavities as may be required to effectproper shaping without undue stretching or thinning of the walls of thesheets. When the shaping operation is completed, it is found thatconsiderable portions of the sheet have been drawn into the cavity withthe result indicated in Fig. 5. This is an important consideration inthe method of this invention because it permits of proper shaping of thesheets while maintaining the thickness of the walls thereofsubstantially uniform, whereby there are no thin or weakened zones whichmight tend to break under subsequent liquid loading.

After the sheets have been shaped as in Fig. 4, the valve 9 is closed.It is then necessary to set the sheets in shaped condition so that, whenthe hydraulic pressure is relieved, they will not tend to lose some ofthe shaping already imparted thereto. This may be accomplished indifferent ways. For example, cold water may be admitted into the moldcavities to ow over the exterior of the shaped sheets and cool them tosetting temperature. If desired, however, a separate valved inlet tubemay lead from the cold water supply into the interior of the pressurebag through the stopper of the latter so that cold water may be admitteddirectly into the pressure bag for the purpose stated, while the valve 9is closed and the valve 13 open to permit the cold water to force thehot water out of the bag, the cold Water being, in turn, forced out ofthe bag by compressed air admitted through tube 17.

In the event that the external cooling and setting is employed, coldwater is permitted to flow into the cavities 2, while compresed air isintroduced through the tube 17 by opening valve 18. The valve 13 beingthen opened, said compressed air will maintain the sheets in formedshape While they are being cooled and set and will also force all of thehot water out of the bag through the outlet tube 12. Meanwhile the gauge22 will indicate the air pressure and the pressure relief valve 23 willact as a safety measure against the building up of excess air pressure.After all of the water has been forced from the interior of the pressurebag, the valve 13 is closed and the compresed air condition within thepressure bag is maintained until the shaped plastic sheets have set. Allof the valves are then closed and the valve opened to vent the interiorof the bag to the atmosphere and when this has been accomplished theformation and setting of the sheets is complete. The molds are thenreleased from their clamped relation and are separated, the pressure bagremoved and the shaped sheets withdrawn from the mold cavities. Theywill then appear as shown in Fig. 6 with their peripheral contour asindicated in dot and dash lines in this ligure.

It will be noted from this ligure that the sheets P have a shaped orchambered portion 27 surrounded by a peripheral n at each of the foursides and with a neck opening 28 extending upwardly from the chamberedportion. The tins of both sections are then trimmed from the dot anddash line form shown in Fig. 6 to the full line form illustrated in thisligure to provide, around the four edges of the sheets, ns 29 ofsubstantially uniform depth. The ns at the top of the sheets are notchedat 30 adjacent each side of the neck opening for reasons' which will bepresently explained. These notches eX- tend downwardly from the upperedges of the sheets to an elevation in spaced relation from thechambered portions 27. Fig. 6 shows the overall contour of the ns as ofrectangular form although the corners may be cut olf if desired asindicated at 31 in Fig. 6A. This is optional.

After the sheets are trimmed as stated, they are placed with their finsin face abutting relation and are marginally heat sealed to one anotherthroughout their entire periphery except at and between the notches 30.This heat sealing is designated 32 in Fig. 7, the stippled portionindicating the extent of the heat sealed zone. It will be noted in thisfigure that this heat sealed zone is at the very periphery of the formedsheets and that it is relatively narrow so that an appreciable width ofthe ns is left between the heat sealing and the chambered portion 27 forreasons hereinbefore explained.

The limitation of the heat sealing to this particular zone is importantand Figs. 8 and 8A show two ways in which such limitation may beaccomplished. Fig. 8 shows two wooden clamping forms 33, the outersurface of which are faced with metal sheeting 34 having contiguousflanges 35. Directly back of these flanges are pipes or chambers 36through which a cooling medium, such as cold water, may be circulated.The fins 29 of the two sections are adapted to be clamped between theclamping forms 33 with the ns extending to the outer edge of the flanges35. After the clamps have been tightly secured in the position shown inFig. 8, heat is applied to the anges in any suitable manner. A Bunsenburner may be used for this purpose or the flanges may be electricallyor otherwise heated to a temperature suflicient to heat seal thoseportions of the tins which lie between the flanges 35. The cooling fluidreferred to, as

` well as the Wooden character of the clamping forms, serve as a barrieragainst the creeping of the heat to the remainder of the width of thelins and thus limit the heat sealing to that portion of the fins whichlies between the anges.

Fig. 8A shows similar wooden clamping forms 33a with flanges 35a setinto the clamping forms and backed up by strips 36a of poor conductivitymetal or other material so as to serve as a barrier against creeping ofthe heat.

By localizing the heat sealed zone in the manner stated, or in any otherappropriate Way of blocking the transmission of such heat to theremainder of the fins, the character or orientation of the plasticstructure is restricted to the zone which is heat sealed, while theorientation of the remainder of the width of the fins remains unchangedand in its original tenacious condition.

The heat sealing described joins the sections throughout their entireperiphery except at the notches and at the neck opening, as indicated inFig. 7. These latter portions are left unsealed to facilitate theattachment of a tubular neck such as indicated at 37 in Fig. 9. Thisneck may be of any appropriate shape but it is shown as cylindrical,with a collar 39 about midway of its length. Above the collar, the neckis screw threaded to receive a cap while that portion 40 below thecollar is adapted to be secured within the neck opening of the assembledplastic sections. The heat sealing of this portion 4t) to said sectionsproved for a long time a very troublesome problem. The difficulty was toheat seal these parts together without seriously changing orientation ofthe relatively thin sheets to which the neck must be attached. However,the present invention solves this problem in the following manner: Theneck is made of tubular stock with a relatively thick wall. This tubularstock is thus sufficiently heavy to permit the exterior cylindricalsurface strata of the portion 40 to be partially fused by theapplication of heat, without fusing the plastic through the entirethickness, ofthe wall. Its exterior is thus heated until its surfacestrata is fused while the underlying portion remains unfused andunaffected by the heat employed. While the portion 40 is in this heated,fused condition it is thrust into the neck openingof the assembledsheets as indicated in dotted lines in Fig. 9. The neck portions of saidsections are then immediately gripped between the jacketed clamps 41 asshown in Fig. 10. The heat of the surface fused section 4l) has beenfound to be enough to fuse the contiguous strata of the neck portions ofthe sheets sufficiently to affect the proper bond through consolidationand coalescence of the abutting strata without, however, detrimentallyaffecting the remainder of the thickness of the sheets. As soon as theparts have coalesced, a cooling tiuid is passed through the jackets ofthe clamps 41 and serves to immediately arrest the fusion of the partsand set them in a permanent joint.

The clamps 41 are then removed and those portions of the fins boundingshaped notches 30 are then heat sealed, `as shown in Fig. 1l, using thetechnique described in conjunction with Figs. 8 or 8A. The step of Fig.11 may be carried out previous to the attachment of the neck 37 but itis found that the neck may be more readily attached if the sealing shownin Fig. 11 is subsequently performed.

Next comes the metal binding of the assembled heat sealed sections. Thisis accomplished by first bending over or returning a portion of thewidth of the fins upon themselves as shown at 29 in Fig. 12.Approximately one-half of the width of the fins is thus returned uponthe remaining half, with the bent tins overlapping one another at thecorners as shown. This folding is appropriate to the rectangular finshape shown in Fig. 6. If the lin shape is as shown in Fig. 6A, thebindings are mitred at the corners and turned in so that the mitrededges meet at each of the eight corners.

After the tins are bent as shown in Fig. 12, metal bindings 42 are thenslipped edgewise over the bent fins, as indicated in the arrows in thisfigure. Each of these bindings is preferably first bent intermediate itswidth into a substantially V-shaped section and each flange of theV-shaped section is returned upon itself. The portions of the ange 43are bent down into face abutting relation. The other tiange 44 is bentto form an open groove 44a, adapted to fit over the bent back portion ofthe corresponding heat sealed fins. Before applying the binding it ispreferably dipped into or otherwise covered with an inert film formingcoating material or housed within a sheath of a material which willprotect the metal binding from corrosion or attack by strong acids oralkalis.

After the bindings have been slipped edgewise over the fins to receivethe heat sealed margins thereof into the grooves 44a, said bindings aresubjected to pressure to bend the flanges thereof into tight grippingrelation with the fins. Each corner may be reinforced by inserting ateach side of the container one or more gussets 45 and 46, the former ofwhich is preferably an organic plastic and the latter of which ispreferably a metallic stamping with a suitable protective coatingagainst corrosion and attack by acids, etc. When the binding is clampedtightly, it grips these gussets at the corners and anchors them firmlyin position.

Fig. 14, a section on the line 14-14 of Figs. 13 and 15 shows veryclearly how the metal binding serves to take actual stresses and strainswhich may be imposed by the liquid load in the container and at the sametime house the heat seal 32 within the contines of the binding at Somelittle distance from the point where the liquid load is carried. Whenthe sections are thus secured together and reinforced, the bindingitself will in a large measure preclude leakage into the joint betweenthe tins and any liquid which may seep along the joint to the heat sealwill be effectively arrested by such seal.

The container thus far described may be used complete 'in this form. lfit is desired to reinforce the binding it may be enclosed within achanneled section 47, indicated in dotted lines in Fig. 14, but underordinary conditions this is unnecessary. When this container is used asa container'of a carboy, such carboy is so constructed as to containchannels for the reception of theV metal bindings and the walls of thesechannels will serve to reinforce the bindings even when such bindingsare made from relative ly thin stock.

Two illustrative forms of carboy housing which may be employed, areshown in Figs. 15 through 20. Figs. 15-18 show a rectangular form. 'Inthis instance, the structure is preferably in the form of a wooden boxprovided at its ends and across its bottom with channels 48 to receivethe metal binding 42. The top wall of the box is made of two sections49, the contiguous edges of which are rabbited at 50 so as to embracethe opposite faces and lower edges of the binding. Battens 51, thecontiguous edges of which are similarly rabbited but in an invertedmanner, abut theopposite faces and cover the upper edges of the bindingsat the top of the container. These battens are secured to the top wall49 of the box housing by screws 52, as shown best in Fig. 17, and theyare secured to one another by screws 53, as shown best in Fig. 18. Thislatter figure shows very clearly how'the binding at the top of thecontainer is housed within the wooden parts of the box and thoroughlyreinforced thereby. The neck of the container extends through theopening 54 in the top of the box, with its fixed collar 39 or otherappropriate abutment resting on the upper surface of the battens 51,whereby the neck is precluded from receding into the interior of thehousing.

As shown in Fig. 16, the end Walls of the box are extended upwardly to apoint above the top of the container neck and a protection bar 56, ofwood or other suitable material, is secured at its opposite ends tobrackets 5'7. In the upright portions of these brackets are formedinverted L-shaped slots 58 through which thumb screws 59 are passed andthreaded into the end walls of the housing. When the bar 56 is in thefull line position shown in Fig. 16 with the horizontal portion of theslots 58 embracing the shank of the thumb screws, these screws may betightened to lock the bar in this position and thus protect the neckagainst contact with extraneous objects. When these thumb screws areloosened the brackets may be shifted slightly to register the verticalportions of the slots 58 therewith, whereupon the brackets and bar maybe swung downwardly into the dotted line position of Fig. 16 to'renderthe screw cap of the container neck accessible.

The structure of Figs. 19 and 20 is a carboy of cylindrical form. Inthis instance the container is made circular instead of in the formhereinbefore described. This may be readily accomplished by merelychanging the shape of the mold cavities. This circular container isreceived within a cylindrical housing 6i) which may be conveniently madeof plywood with a solid bottom 61 and a top, constructed in the samegeneral manner as in Figs. 17 and 18 but of circular form. In this casestrips 62 are secured in upstanding spaced relation interiorlyof and atopposite sides of the housing, as shown best in Fig. 20,

to provide between them channels 42a and the bottom 61 is provided witha registering'diametric slot 42 to receive the bindings of thecontainer.

v Any appropriate cover may be provided for a carboy of this latter typesuch, for example, as the slip cover 63 Vshown in Fig. 19 which has aninternal annular reinforcing ring 64 and Areinforcing battens 65 toimpart added Vstrength to the cover and to permit the stacking of suchcarboys one upon the other for compact storage or shipment. Appropriatecatches may be used to secure the cover to the body of the housing.

The initial formation or shaping of the plastic sheets to provide thechambers or cavities 27 therein has been hereinbefore described asaccomplished by use of a pressure bag. This formation of the sheets may,however,

9 be carried out without such a bag. This may be done by initiallymarginally heat sealing the sheets to one another, as indicated at 66 inFig. 21, and clamping a temporary stopper 67 into the open space left atthe top of the sheets. This assembly constitutes in itself a bag whichmay be clamped, as hereinbefore described in conneetion with Figs. 2 and4, between the molds and the method of this invention thereupon carriedout as before except that the hot water is introduced directly into thespace between the sheets. When this system is used the clamping of themolds together will hold sufficient hydraulic pressure to permit ofshaping of the sheets as hereinbefore described, although the use of aseparate pressure bag is preferred. When the practice of Fig. 21,.

is employed the heat sealing 66 is cut away after the sheets are shapedand heat sealing corresponding to that indicated at 32. in Fig. 7 iscarried out as previously stated.

In the foregoing detailed description, reference has been made primarilyto the employment of polyethylene as the plastic employed for thisplastic is peculiarly adapted for use in carboys which are to containstrong acids and alkalis. I am aware of no prior procedure which makesit possible to employ this plastic for the purpose stated for, while theplastic may be heat sealed, heat sealing is not enough for when heatsealed its strength in the .zone of such sealing is seriously impaired.The illustrative showing hereinbefore made illustrates how this plasticmay be satisfactorily employed. I am aware, however, that other plasticssusceptible to heat sealing may be availed of without departing fromthis invention.

Disclosure herein made includes numerous features of novelty some ofwhich may be employed without necessarily employing all. The inventionis therefore to be understood as not limited to all of these features orto the particular method step sequences or apparatus employed incarrying out the methods described. The present invention is thereforeto be understood as full commensurate with the appended claims.

Having thus fully described my invention, what I claim as new and desireto secure by Letters Patent is:

1. The method of making a container which comprises: bringing intoregistration the chambered portions of two plastic container sectionswith flat ns which border the chambered portions in initial contact,heat sealing portions of the ns remote from said chambered portionswhile leaving the greater part of the remaining portions of the width ofsaid ins unsealed and unaffected by the heat of such sealing and alsoleaving an unsealed neck opening between the fins, and thereafterenclosing said remote heat sealed portions of the ns as well as thegreater portion of the said unaffected width of said fins within ametallic binder with both the fins and the binder returned uponthemselves in spaced relation to said remote heat sealed portions of thens and the chambered portions of said sections.

2. The method of claim 1 which includes a further step of sealing aseparate neck to the ns in the neck opening.

3. The method of claim 1 wherein the said remote portions of the finsare the marginal portions of said ns.

4. The method of claim l which includes the additional step ofthereafter enclosing the metal binder within a close fitting channel.

5. The method of claim 1 wherein ethylene.

6. The method of making a container which comprises: bringing intoregistration the chambered portions of two plastic container sectionswith ins bordering the chambered portions in facial contact, heatsealing the marginal portions only of said fins to one another while theheat sealed marginal zone is localized by blocking the transmission ofheat therefrom to the remainder of the width of the fins, and thereafterenclosing such heat sealed the plastic is polymarginal portions of thetins as well as the greater portion of the width of said fins within ametallic binder.

7. The method of claim 6 wherein both the tins and the metallic binderare returned upon themselves in spaced relation to both the sealedmarginal zone of the tins and the chambered portions of the containersections.

8. The method of making a container which comprises: bringing intoregistration the chambered portions of two plastic container sectionswith at tins bordering the chambered portionsinto facial contact,uniting the marginal portions of said tins but leaving a neck openingbetween said sections, exteriorly heating a portion of the tubular neckuntil only the surface strata thereof is fused, introducing the surfacefused portion of the neck while said strata remains in fused conditioninto the neck opening between said sections, applying pressure to saidsections about the neck opening until the heat of the fused strata ofthe neck has fused the contiguous strata of the sections at the neckopening and effected a coalesced union between contacting portions ofthe neck and sections.

9. The method as claimed in claim 8 which includes the additional stepof cooling all of said fused portions before fusion can penetrate thethickness of the sections at the neck opening.

10. The method of making a container which comprises: bringing intoregistration the chambered portions of two plastic container sectionswith ilat iins bordering the chambered portions into facial contact,thereafter heat sealing the marginal portions of the lins to one anotherwhile leaving the remainder of the width of the fins in unsealedcondition and also leaving a neck opening, heat sealing the neck to theopposing fins at said opening, introducing the heat sealed margins ofthe tins into a groove in a metal binding and in which groove the heatsealed margin is completely received, thereafter closing said groove,and thereafter conjointly bending the remainder of the width of thebinding and the fins remote from the heat sealed margin thereof tofurther clamp and grip the ns within the binding.

11. The method of claim 10 which includes the additional step ofbringing a channel into position to embrace the binding to reinforce thelatter.

12. The method of claim l0 which includes the additional step ofenclosing the container within a housing provided with channels toreceive the bound edges of the container.

References Cited in the le of this patent UNITED STATES PATENTS 761,890Kepler June 7, 1904 1,452,039 Gravell Apr. 17, 1923 1,518,194 GravellDec. 9, 1924 1,841,265 Husa Ian. 12, 1932 1,962,900 Hirsch June 12, 19342,083,479 Speare June 8, 1937 2,152,467 Crosby Mar. 28, 1939 2,221,470Brown Nov. 12, 1940 2,289,618 Young July 14, 1942 2,404,766 Hanson etal. July 23, 1946 2,435,251 Tome Feb. 3, 1948 2,438,685 Stevens Mar. 30,1948 2,441,778 Traver May 18, 1948 2,478,121 Morner Aug. 2, 19492,488,212 Lloyd Nov. 15, 1949 2,494,905 Schumann `Ian. 17, 19502,569,534 Netz Oct. 2, 1951 2,581,763 Hickler Jan. 8, 1952 2,584,632Southwick Feb. 5, 1952 2,620,944 Stahl Dec. 9, 1952 2,702,034 WalterFeb. 15, 1955 FOREIGN PATENTS 272,608 Great Britain June 17, 1927

1. THE MEHTOD OF MAKING A CONTAINER WHICH COMPRISES: BRINGING INTOREGISTRATION THE CHAMBERED PORTIONS OF TWO PLASTIC CONTAINER SECTIONSWITH FLAT FINS WHICH BORDER THE CHAMBERED PORTIONS IN INITIAL CONTACT,HEAT SEALING PORTIONS OF THE FINS REMOTE FROM SAID CHAMBERED PORTIONSWHILE LEAVING THE GREATER PART OF THE REAMINING PORTIONS OF THE WIDTH OFSAID FINS UNSEALED AND UNAFFECTED BY THE HEAT OF SUCH SEALING AND ALSOLEAVING AN UNSEALED NECK OPENING BETWEEN THE FINS, AND THEREAFTERENCLOSING SAID REMOTE HEAT SEALED PORTIONS OF THE FINS AS WELL AS THEGREATER PORTION OF THE SAID UNAFFECTED WIDTH OF SAID FINS WITHIN AMETALLIC BINDER WITH BOTH THE FINS AND THE BINDER RETURNED UPONTHEMSELVES IN SPACED RELATION TO SAID REMOTE HEAT SEALED PORTIONS OF THEFINS AND THE CHAMBERED PORTINS OF SAID SECTIONS.